Metal ingots

ABSTRACT

A metal ingot (pig) of a trapezoidal cross section having on each oblique side face at least one tooth and a recess for interlocking a plurality of the ingots in a row through similar teeth and recesses, said ingots being laid alternately so that the adjacent ingots are inverted relative to each other. The teeth and recesses prevent adjacent ingots in one row from longitudinal and transverse displacement.

United States Patent 11 1 Chernichenko et al.

[ 1 Aug. 26, 1975 l l METAL INGOTS [22] Filed: Apr. 26, 1974 [2]] Appl.No.1 464,981

Related U.S. Application Data [63] Continuation of Ser. No. 269,186,July 5, 1972,

abandoned.

[30] Foreign Application Priority Data July 7, 1971 U.S.S.R i. 1678086[52] US. Cl U 29/187; 29/1875 [51] Int. Cl. 822d 7/00 [58] Field ofSearch 29/187, 187.5

[56] References Cited UNITED STATES PATENTS 3,100,142 8/1963 English eta1. 29/187 3,154,391 10/1964 Morris 29/187 X FORELGN PATENTS ORAPPLICATIONS 686,821 5/1964 Canada 29/187 618,247 4/1961 Canada 29/187Primary ExaminerL. Dewayne Rutledge Assistant Examiner--O. F.Crutchfield Attorney, Agent, or FirmHolman & Stern [57] ABSTRACT A metalingot (pig) of a trapezoidal cross section having on each oblique sideface at least one tooth and a recess for interlocking a plurality of theingots in a row through similar teeth and recesses, said ingots beinglaid alternately so that the adjacent ingots are inverted relative toeach other. The teeth and recesses prevent adjacent ingots in one rowfrom longitudinal and transverse displacement.

3 Claims, 13 Drawing Figures PATENTED AUBZ 6 I975 SHEET 2 BF 3 F ILZQMETAL INGOTS This is a continuation of application Ser. No. 269,186filed July 5, 1972, now abandoned.

FIELD OF THE INVENTION The present invention relates to metallurgy orfoundry and, more particularly, the invention relates to metal, forexample aluminium, ingots or pigs adapted for assembly in stable stacksor bundles to be transported by any suitable transport means.

BACKGROUND OF THE INVENTION On casting ingots in non-detachableopen-type moulds, technologically advantageous are pigs of a trapezoidalcross section with rectangular bases and oblique side faces. Such ingotsare easily removed from the moulds. The stacks are assembled from theseingots and laid in horizontal rows in which the ingots are inverted withrespect to each other and the ingots have a high density and, therefore,a high specific weight.

However, such ingots have no elements for their interconnection in thetransverse direction in one horizontal row so that the stacks formed ofthese ingots are likely to become loose. Therefore, when forming stacks,the ingots are laid crosswise so that the ingots of the upper layer areturned at an angle of 90 to those in the next lower layer. Yet, evensuch composition of the ingots combined with binding by high-strengthmetallic bands does not provide the strength required so that thestacks, in the process of transportation and during the loading andunloading the stack are maintained integral and breaks and the ingotsbecome loose.

The increasing rise of production of pig metal and the high cost ofloading and unloading operations (time expended) present a problem inthe development of an ingot that will ensure formation of a strong and acompact stack requiring no complicated and expensive, high-strengthdurable binders.

The basic difficulty in the development of such an ingot consists inthat it is to be cast in an open-type and nondetachable mould.

When casting metal in such a mould, the surface of the major base of theingot is always a pouring surface, and no projections or recesses can beformed thereon. In this connection, the elements for connecting the adjacent ingots in one horizontal row and the adjacent horizontal rows (bya vertical line) can be made only on the longitudinal side faces of theingot and on its minor base, in which case they can be oriented only tothe side of the lower base (taking into account the technologicalcasting angle to permit removal from the mold).

Known at the present time are pigs or ingots provided with elements forinterlocking adjacent pigs in a single horizontal row. When the pigs areinverted with respect to each other, these elements provide for meshingof the pigs in the transverse and longitudinal directions. Such a pig,for example, is disclosed in Canadian Pat. No. 609,336.

The prior art pig has a rectangular base with an upwardly directedrectangular projection located along the base and has a lower width thanthat of the base so that at both sides of the projection, along the longsides of said rectangular base, there remain platforms which areinclined inside, to the rectangular projection. These oblique platformsform shoulders and grooves providing for an engagement of the pigs ofone horizontal row when laying them alternately and inverted withrespect to each other.

In order to prevent the ingots from longitudinal displacement in ahorizontal row, at the midpoint of each platform there are providedhorizontal portions, in which case on one side of the ingot thehorizontal portion is made at the crest level of the shoulder, and onthe other side thereof, it is made at the bottom level of the groove.The ingot is provided with teeth and respective recesses on the base ofthe rectangular projection used for connecting the ingots in thehorizontal row and for forming a stack or bundle. The ingots in thehorizontal row which are adjacent in a vertical line are disposed in thesame direction.

The main disadvantage of such an ingot is, first, that, in laying eachnext horizontal row in a stack, the ingots must be turned in ahorizontal plane through an angle of 180"; second, that the angle ofengagement is much greater than the angle of friction of the metal ofthe ingot at a low meshing depth so that reliable bending of the stackis necessary; and, third, the platforms along the longitudinal sides ofthe ingot form cavities on the surface of the stack which reduce itsspecific weight.

Also known in the art are ingots having elements for interlocking theadjacent ingots in one horizontal row made on platforms or flangesprovided along the longitudinal sides of the ingot (see US. Pat. Nos.3,140,926 and 3,154,391; cl. 29-184). These ingots are disadvantageousin that they have no elements for interlocking the adjacent horizontalrow in a vertical direction, and also in that the longitudinal platformsreduce the specific weight of the stack.

As mentioned above, the most advanced, from the viewpoint of the castingtechnology, are ingots having a trapezoidal cross section andrectangular major and minor bases which provide for the highest densityand specific gravity of the stack. The disadvantage of these ingots isthat up to now elements have not been developed which would provide forinterlocking of the adjacent ingots in one horizontal row and of theadjacent rows in the stack in a vertical direction and elements will notprotrude beyond the limits of the overall dimensions of the ingots,although attempts have been made to make such elements.

In this connection, of particular interest is the ingot havingrectangular base portions and a trapezoidal cross section in which oneoblique side face has a transverse shoulder through the whole height ofthe ingot, while the other face has a through groove (see US. Pat. No.3,081,87l cl. 206-65). Said shoulder and groove have a similar shape,the groove being inverted with respect to the shoulder.

The ingots are laid in a single horizontal row and are inverted relativeto each other so that the shoulder of one ingot enters the groove of theother thereby preventing them from relative longitudinal displacement.

This ingot is disadvantageous in that it has no elements providing fortransverse engagement of the adjacent ingots in one horizontal layer aswell as for engagement of the adjacent horizontal rows in a verticaldirection. This makes it necessary to put one row on the other, whileturning it through an angle of in a horizontal plane so as to preventtransverse and longitudinal displacement of one horizontal row withrespect to the other.

The disadvantages of this ingot are: in the first place, the absence ofelements for interlocking the adjacent ingots in one horizontal row inthe transverse direction and, in the second place, and as a result, thenecessity in cross-like laying of ingots in the horizontal rows adjacentalong the vertical, in which case mechanization of the process ofassembly of the ingot into a stack gives rise to considerabledifficulties. Moreover, a stack of such ingots requires strong andcomplex binding means, while the presence of shoulders on the surface ofthe lower base portion hinders the transportation of the ingot duringits manufacture and leads to an undesirable increase in the specificpressure on the supporting surface of the transport devices, forexample, on the floor of a railway car.

SUMMARY OF THE INVENTION An object of the present invention is toprovide a metal ingot (pig) which will have a shape ensuring tightassembly of the ingots into a stack having a higher density and strengththan the stacks formed by known ingots.

Another object of the invention is to provide for interlocking elementsfor an ingot which do not project beyond the overall dimensions of thelarger or major rectangular base of this ingot which has a trapezoidalsection and rectangular base portions, and is most advanced andcompatible to casting and stacking from a technological point of view.

Still another object of the invention is to provide for interlockingelements on the oblique side face of an ingot which would provide forrigid, locking, engagement of the adjacent ingots in a horizontal row inboth longitudinal and transverse directions.

Yet another object of the invention is to provide for interlockingelements on an ingot on the minor rectangular base which will ensureuniform and permanent engagement of the ingots laid one upon anotherthrough said bases, in which case the assembly of the ingots is possibleonly when turning (rotating) the ingot being laid about its longitudinalaxis through an angle of 180, so that turning through an angle of 180 ina horizontal plane is not necessary.

These and other objects are attained by providing metal ingots (pigs)adapted for assembly in a stack (bundle), each ingot having rectangularbases, a trapezoidal cross section and oblique side faces provided withinterlocking elements preventing two adjacent ingots in a common rowfrom mutual longitudinal displacement. According to the invention, eachoblique side face of the ingot has at least one said interlockingelement or tooth and an adjacent recess, said teeth and recesses meshingwith the corresponding teeth and recesses on the adjacent invertedingots and preventing their mutual respective displacement in atransverse direction.

The ingots with the interlocking elements of said shape are laid asdense (tight) horizontal rows in stacks (bundles) which have adequatestrength and do not tend to become disassembled during transportationand loading.

It is expedient that the tooth be formed normal to the major base of theingot and partially protrudes beyond the oblique side face within theoverall dimensions of the major base, while the recess adjacent to thetooth has a complimentary shape corresponding to that of the invertedtooth" and is limited in a lateral direction of the ingot by the innersurface of the tooth and by the surface of a groove in the ingot bodysimilar in shape to the projected portion of said tooth and disposedwithin the oblique side face of the ingot, while in the longitudinaldirection the recess is limited by the lateral sides of said grooves.Such a shape of the ingot contributes to an increase in the specificweight of the stack (bundle) by eliminating hollow spaces between theprojecting portions on the side faces of the stack and prevents theingots from mutual longitudinal displacement in one horizontal row.

It is expedient that formed between the inner surface of the tooth andthe line of its height is an angle of engagement which would be lowerthan the angle of friction of the ingot metal,

this provides for reliable engagement of the adjacent ingots of the rowin a lateral direction.

The minor base of the ingot may be provided with projections andrecesses arranged in a staggered order, in which case their totalnumber, both across and along the base, must be even.

The provision of the projections and recesses on the minor base of theingot provides for connection of the horizontal rows in the stack, inwhich case, the staggered order to disposition of the projections andrecesses and their even number both along the length and width of thebase makes it possible to lay the ingots in rows one upon the otherwithout turning (rotating) them in a horizontal plane through an angleof 180 relative to each other, and ensures additional engagement of theingots in the horizontal rows in a transverse direction.

Other objects and advantages of the invention will be apparent from thefollowing detailed description of examples of making metal pigs oringots, reference being made to the accompanying drawings, in which:

BRIEF DESCRIPTION OF THE DRAWING FIG. I is a side elevational view of ametal ingot with one interlocking element on each side face;

FIG. 2 shows the same metal ingot in a plan view;

FIG. 3 is a sectional view taken along the line IIIIII in FIG. 2;

FIG. 4 is a sectional view taken along the line IVIV in FIG. 1;

FIG. 5 is a side elevational view of another metal ingot with twointerlocking elements on each side face; FIG. 6 is a plan view of themetal ingot shown in FIG. 5

FIG. 9 is a side elevational view of still another metal ingot with twointerlocking elements on each side face, said elements being disposedwithin the dimensions of the shoulders;

FIG. 10 is a plan view of the metal ingot shown in FIG. 9;

FIG. I1 is a sectional view taken along the line XIXI in FIG. 9;

FIG. 12 is a sectional view taken along the line XII- XII in FIG. 9; and

FIG. 13 shows the metal ingots assembled into a stack (bundle) a portionshown in section made in a transverse direction to a vertical planealong the line of the interlocking elements.

DESCRIPTION OF THE PREFERRED EMBODIMENTS A metal ingot 1 (FIGS. 1, 2, 3and 4) has a major rectangular base 2, a minor rectangular base 3 andoblique side faces'defining a trapezoidal cross section indicated at Sin FIG. 4.

Provided on each oblique side face 4 is an interlocking element 6consisting of a tooth 7 and an inner recess 8 adjacent thereto in atransverse direction of the ingot 1; said tooth and recess beingengagable with a similar tooth and recess of an adjacent ingot, which isinverted relative to the former ingot, and preventing their mutuallongitudinal and transverse displacement in a common horizontal row; seeFIG. 13.

The tooth 7 extends normal to the major rectangular base 2 of the ingotl and partially protrudes beyond the oblique side face 4 but within theoverall dimensions of the major rectangular base 2. The recess 8adjacent to the tooth 7 has a shape corresponding or complimentary tothat of the inverted tooth 7 and is limited in the transverse directionof the ingot l by an inner surface 9 of the tooth 7 and the surface 10of a groove 11 formed in the body of the ingot 1 within the limits ofthe oblique side face 4 and corresponding in shape to the portion of thetooth 7 projecting beyond this oblique face, while in the longitudinaldirection it is limited by side faces 12 of the groove 11.

The tooth 7 is limited, in the longitudinal direction of the ingot l, byoblique faces 13 having the same angle of inclination as the side faces12 of the groove 11.

The height h of the tooth 7 and the magnitude h of the recess 8 areequal to one half of the full height H of the ingot 1 so as to permitmutual engagement of the tooth 7 of the ingot I with the identical toothof an adjacent ingot in a horizontal row, the corresponding tooth 7 ofthe adjacent ingot being inverted with respect to the former. The value(depth) of said engagement of the teeth must be at least twice as largeas the maximum permissible height of the ingot I. In this case, whencasting an ingot I having a minimum permissible height, the magnitude ofengagement of the teeth 7 of the adjacent ingots inverted relative toeach other and disposed on a single supporting surface is equal to onemagnitude of the maximum permissible height H of the ingot l which isquite sufficient for stable engagement between the ingots.

The inner surface 9 of the tooth 7 (see FIG. 3) forms with the verticalaxis of or height of the tooth 7, an angle of engagement 0: which islower than the angle of friction of the ingot metal thereby ensuringtransverse fixed engagement of the adjacent ingots which is practicallynondetachable in this direction. The ingots can be disconnected onlywhen the tooth 7 is completely withdrawn from the recess 8 in thedirection perpendicular to the ingot bases. Provided on the minorrectangular base 3 of the ingot I are flanges (steps) 14 and grooves(recesses) 15 arranged in a staggered order. In this case, the totalnumber of the flanges I4 and grooves 15 is equal both along and acrossthe base 3, these flanges 14 have a length and width less than thecorresponding dimensions of the grooves 15 and are not connected withone another.

Such an arrangement and number of the flanges l4 and grooves I5 by thelength and width of the minor rectangular base 3 provide forinterlocking of the ingots laid (stacked) on each other through theirrectangular bases 3 in the transverse and longitudinal directions, inwhich case engagement can be effected in any longitudinal direction,both by turning the ingots rela tive to each other in a horizontal planethrough an angle of and without this inversion, this facilitatesmechanization of the operation of assembly of the ingots into a stack.

The length of some flanges 14 can be much less than the length of thegrooves 15 so that a transverse gap 16 (FIGS. 1 and 2) is formed betweenthe flanges 14 which is sufficient to accommodate placing of bindingmaterial (steel band, wire, etc.) to retain a stack integral.

The grooves 15, FIGS. l-4 have a depth equal to the maximum permissibleheight H of the ingot l, in which case the magnitude h of the recess 8exceeds the height h of the tooth 7 by at least the depth of the groove15. Such a relation between the depth of the grooves 15, the magnitude hof the recess 8 and the height h of the tooth 7 provides for permanentand uniform engagement of the flanges l4 and grooves 15 of the ingot 1with the similar elements of the ingot I laid on the former ingot withits minor rectangular base 3 along a vertical line of the horizontal rowthereby connecting one horizontal row with the other; see FIG. 13.

To ensure convenient transportation by a fork lift loader, the ingot 1may be provided with end shoulders 17.

In another embodiment of the invention (FIGS. 5 and 6) each oblique sideface 4 of the ingot 18 is provided with two interlocking elements 6.This ingot is shown without shoulders 17 but can incorporate them as inthe previously described embodiment.

The ingot 18 provides for greater stable and reliable engagement of theadjacent ingots in one horizontal row by preventing their rotation inthe plane of the oblique side face 4.

The ingot 19 (FIGS. 7 and 8) also has two said interlocking elements 6,however, these elements are located at the ends of the ingot so that therespective teeth 7 and the recesses 8 face the shoulders 17. Thisimproves the technology and facilitates casting of the ingot. In thiscase the recess 8 is limited in the longitudinal direction of the ingotonly by one side face 12 of the groove II.

The final modification of the invention is shown by an ingot 20 (FIGS.9, 10, 11 and 12) which, like the ingots l8 and 19, has two interlockingelements 6 arranged on each oblique side face 4 within the zone of theshoulders 17 at the extreme ends of the ingot. In this embodiment of theinvention, that functions as do the other embodiments the shoulders 17are equal to the height of the tooth 7, while the recess 8 is formed inthe shoulders 17 and in the cross section of the ingot 20 (FIG. 12) isbeyond the zone of the oblique side face 4. The disposition of saidinterlocking elements 6 is advantageous from the technological castingpoint of view compared to the ingots l8 and 19 both during the castingand in the process of making the casting moulds.

In this embodiment the flanges 14 and grooves 15 are arranged in astaggered relation on the minor rectangular base 3 so that in thelongitudinal direction of said base there is one flange 14 and onegroove 15, while in the transverse direction there are two flanges l4and grooves I5. Such an arrangement of the flanges and grooves, whilehaving all the advantages of the abovedescribed modifications, featuresanother technological advantage in the process of casting which consistsin that at longitudinal disposition of one flange l4 and one groovealong the entire length of the minor rectangular base 3, the shrinkageof the ingot in the casting mould offers no difficulties.

The above-described ingot l and its modifications, i.e., the ingots 18,I9 and are adapted for assembly in a stack (bundle) 21 (FIG. 13), inwhich case the stacks formed from said ingots have the same specificweight and strength and are superior to the identical characteristics ofthe stacks of the prior art ingots mentioned in the introductory part ofthis description.

A stack of the above-described ingots may be formed in two ways:

In order to provide for convenient transporation of the stack by a forklift loader without using special pad members (bars, pillows), the firstrow is formed of four ingots 22 (FIG. 13) laid with their minor base 3on a supporting surface. The second row is formed of five ingots laid inthe same direction as the ingots of the lower row, in which case theextreme (outer) ingot 23 of the second row is laid with its minorrectangular base 3 on the major rectangular base 2 of the extreme ingot22 in the lower row. The ingot 24 of the second row is inverted relativeto the ingot 23 through 180 about its longitudinal axis and is connectedthereto through an interlocking element 6, in which case the tooth 7 ofthe ingot 24 enters the recess 8 of the ingot 23, while the tooth 7 ofthe ingot 23 enters the recess 8 of the ingot 24. The next ingot of thesecond row is laid and connected similarly to the ingot 23 to the end ofthe row. In this example the second row is not connected with the firstrow by means of the above-described flanges 14 and grooves 15 on theminor rectangular base 3 and binds it only due to overlapping the jointsof the ingots 22 by the ingots 23, 24, etc. of the second row, in whichthe ingots are connected to each other through the above-saidinterlocking elements 6. I

The third row is formed in the same manner as the second row of fiveingots laid in the same direction'as the preceding rows. The ingot 25 ofthis row is laid with its major rectangular base 2 on the majorrectangular base 2 of the ingot 23 of the second row, while the ingot 26of the third row is (inverted) turned about its longitudinal axisthrough an angle of 180 and is laid so that its interlocking element 6enters into engagement with the identical element 6 of the ingot 25,while the flanges 14 and the grooves 15 on the minor rectangular base 3engage the identical flanges 14 and grooves 15 of the ingot 24. In thiscase, owing to the fact that the ingot 26 descends below the ingot 25 bythe depth of the groove 15, the teeth 7 and the recesses B of these twoingots will come into a tight contact, while their oblique side faces 4will be wedged relative to each other.

Due to the fact that the connection of the ingots of third horizontalrow is identical to the connection of the ingots 25 and 26, this rowrigidly binds the stack in the transverse direction like all the rowsuneven by height in this modification of the stack.

The stack 21 is bound by a band or wire 27 in one direction in one ortwo rows, in which case the binding material must have a strengthsufficient only for hold ing the lower and upper rows of the stackduring sea transportation. When these stacks are transported by asurface transport, the binder means may not be necessary.

In the second modification of the stack of the abovedescribed ingots(not illustrated), the first (lower) row is formed in the same manner asthe second row of the first modification. In this case it is necessaryto use pad materials both directly at places of forming the stacks andon the transport vehicles.

The stack of the above-described ingots may have a high volume due to agreat number of ingots in the horizontal rows and the number of thehorizontal rows in the stack.

Since in the process of the assembly in a stack, the proposed ingots donot require manipulation in a horizontal plane either through an angleof 180 or through an angle of with respect to the adjacent ingot, theprocess of stacking can easily be mechanized.

We claim:

1. An ingot adapted for assembly in a stack comprisingz a transversetrapezoidal cross section including a flat major base of rectangularshape, a rectangular minor base and oblique side surfaces; engagementelements at opposite sides on each of said oblique side surfaces andcomprising at least one tooth (7) disposed outside the oblique sidesurfaces and arranged in a transverse direction relative to said ingot,and a recess (8) adjacent said tooth and complimentary in shape to thelatter for engagement with a similar recess and a corresponding tooth ofan adjacent identical ingot which has been inverted and engaged whenforming a stack of ingots; said recess comprising a groove (11) inwardlyof the tooth and limited by two flanking surfaces (12) and by an innersurface (9) of the tooth in the transverse direction and a portion of aside surface (10) of said ingot corresponding to the length of saidtooth; the minor base including flanges (l4) and grooves (15) inalternating relation with one another, the number of flanges and groovesbeing equal.

2. An ingot as claimed in claim 1, in which the height (h) of said toothand height (h') of each said recess 8) is greater than half the height(H) of said ingot.

3. An ingot as claimed in claim 1, in which the inner surface (9) ofsaid tooth (7) relative to a plane coinciding with height (H) of thetooth is inclined at a prescribed angle, whereby interdigitated teethand recesses in a stack are firmly wedged together.

i III i

1. AN INGOT ADAPTED FOR ASSEMBLY IN A STACK COMPRISING: A TRANSVERSETRAPEZOIDAL CROSSSECTION INCLUDING A FLAT MAJOR BASE OF RECTANGULARSHAP, A RECTANGULAR MINOR BASE AND OBLIQUE SIDE SURFACES, ENGAGEMENTELEMENTS AT OPPOSITE SIDES ON EACH OF SAID SURFACES AND COMPRISING ATLEAST ONE TOOTH (7) DISPOSED OUTSIDE THE ODLIQUE SIDE SURFACES ANDARRANGED IN A TRANSVERSE DIRECTION RELATIVE TO SAID INGOT, AND A RECESS(8) ADJACENT SAID TOOTH AND COMPLIMENTARY IN SHAPE TO THE LATTER FORENGAGEMENT WITH A SIMILAR RECESS AND A CORRESPONDING TOOTH OF ANADJACENT IDENTICAL INGOT WHICH HAS BEEN INVERTED AND ENGAGED WHENFORMING A STACK OF INGOTS, SAID RECESS COMPRISING A GROOVE (11) INWARLYOF THE TOOTH AND LIMITED BY TWO FLANKING SURFACES (12) AND BY AN INNERSURFACE (9) OF THE TOOTH
 2. An ingot as claimed in claim 1, in which theheight (h) of said tooth and height (h'') of each said recess (8) isgreater than half the height (H) of said ingot.
 3. An ingot as claimedin claim 1, in which the inner surface (9) of said tooth (7) relative toa plane coinciding with height (H) of the tooth is inclined at aprescribed angle, whereby interdigitated teeth and recesses in a stackare firmly wedged together.